Wire mesh pallet and method of producing a wire mesh pallet

ABSTRACT

A wire mesh pallet is presented. The wire mesh pallet includes a wire mesh, the wire mesh including a plurality of integral legs, the legs formed by bending of the wire mesh. The wire mesh pallet further includes at least one truss device, the truss device capable of limiting or controlling an amount of flex of said wire mesh pallet.

CROSS REFERENCE TO RELATED APPLICATIONS

The present application claims the benefit of U.S. Provisional PatentApplication No. 61/056,617, filed on May 28, 2008, which is incorporatedherein by reference in its entirety.

BACKGROUND

Pallets are used to ship and store a variety of goods. There are severalhundred million new pallets produced each year in North America andabout 1.2 billion are in use at any given time. Over 90 percent ofpallets are made from wood or wood composite with the balance being madefrom plastic, metal and paper. It is estimated that there are over 3,200companies in North America producing pallets, from small “garage-type”operations to large companies producing several million pallets peryear. There is one conventional size (“Footprint”) pallet, measuring 48inches by 40 inches that represents about 30 percent of all palletsproduced each year. There are another nine “footprints” representing 60percent of the annual pallet production. The remaining 40 percent of themarket includes custom sizes, built to specific end customerrequirements.

SUMMARY

Conventional pallets, such as those explained above, suffer from avariety of deficiencies. Among the many shortcomings of conventionalpallets are their weight, the space required to store the pallets, theirflammability, their susceptibility to bugs and pests, their inability tobe kept clean, the fact that they can result in splinters to handlersand products, labor intensive manufacturing, relatively short life cycleand little or no scrap value.

Embodiments of the invention significantly overcome such deficienciesand provide mechanisms and techniques that provide a wire mesh palletand a method of producing a wire mesh pallet. The wire mesh pallet isrecyclable, lightweight, stackable in a nesting fashion, fire resistant,bug and pest resistant, sanitary, splinter free, strong, lower in costto manufacture, durable and has scrap value.

Note that each of the different features, techniques, configurations,etc. discussed in this disclosure can be executed independently or incombination. Accordingly, the present invention can be embodied andviewed in many different ways. Also, note that this summary sectionherein does not specify every embodiment and/or incrementally novelaspect of the present disclosure or claimed invention. Instead, thissummary only provides a preliminary discussion of different embodimentsand corresponding points of novelty over conventional techniques. Foradditional details, elements, and/or possible perspectives(permutations) of the invention, the reader is directed to the DetailedDescription section and corresponding figures of the present disclosureas further discussed below.

BRIEF DESCRIPTION OF THE DRAWINGS

The foregoing will be apparent from the following more particulardescription of preferred embodiments of the invention, as illustrated inthe accompanying drawings in which like reference characters refer tothe same parts throughout the different views. The drawings are notnecessarily to scale, emphasis instead being placed upon illustratingthe principles of the invention.

FIG. 1 illustrates a first cross sectional view of a wire mesh pallet inaccordance with embodiments of the invention;

FIG. 2 illustrates a second cross sectional view of a wire mesh palletin accordance with embodiments of the invention;

FIG. 3A illustrates a top view of a first embodiment in accordance withembodiments of the invention;

FIG. 3B illustrates a top view of a second embodiment in accordance withembodiments of the invention;

FIG. 3C illustrates an end view of the wire mesh of FIG. 3B;

FIG. 4A comprises an end view of a wire mesh pallet in accordance withembodiments of the invention;

FIG. 4B comprises a partial end view of the wire mesh pallet of FIG. 4A;

FIG. 5A comprises an end view of a wire mesh pallet including a runnerin accordance with embodiments of the invention;

FIG. 5B comprises a partial end view of the wire mesh pallet of FIG. 5A;

FIG. 5C comprises a partial cross-sectional view of the wire mesh palletof FIG. 5A;

FIG. 6 comprises an end view of a wire mesh pallet including a shorttruss wire in accordance with embodiments of the invention;

FIG. 7 comprises an end view of a wire mesh pallet including anelongated truss wire in accordance with embodiments of the invention;

FIG. 8 comprises an end view of a wire mesh pallet including a trussclip in accordance with embodiments of the invention;

FIG. 9A comprises an end view of a wire mesh pallet including areinforcement wire in accordance with embodiments of the invention;

FIG. 9B comprises a partial end view of the wire mesh pallet of FIG. 9A;and

FIGS. 10A and 10B comprise a flow diagram of a particular embodiment ofa method of producing a wire mesh pallet in accordance with the presentinvention.

DETAILED DESCRIPTION

The present invention comprises a wire mesh pallet. Instead ofconventional wooden pallets, a pallet is formed from a wire mesh. Thewire mesh is bent to form a plurality of legs at predetermined places inthe mesh resulting in a pallet formed from a single piece of mesh. Theinvention is a unique way to construct a pallet by maximizing thestrength and stiffness of the product at the lowest possible weight andefficiency to manufacture, thereby making the sale of the productpossible in comparison with pallets made from other materials.

The presently disclosed wire mesh pallet is 100 percent recyclable andlightweight—about one half the weight of a conventional wooden pallet.The wire mesh pallet is stackable. The pallets can be nested whenstacking, allowing more than double the number of pallets to be shippedfrom the factory and on return loads. The wire mesh pallet is also fireresistant. The wire mesh pallets will not burn, allowing pallets to bestored indoors and reducing insurance costs. The wire mesh pallet willnot harbor bugs or pests and can be certified for export shipmentswithout treatment. The wire mesh pallet is also easier to clean and keepclean, and produces no splinters to damage hands or product. The wiremesh pallet offers higher strength and stiffness as well as low laborcost to produce. Further, the wire mesh pallet has a long life cycle andis easy to repair as well as having scrap value at end of life cycle,with no disposal costs.

Referring now to FIGS. 1-3C, different views of different embodiments ofa wire mesh pallet 10 is shown. A piece of wire mesh is bent to formfirst surface area 12, first leg 20, second surface area 14, second leg22, third surface area 16, third leg 24 and fourth surface area 18.First leg 20 includes a first side portion 20 a, a bottom surface 20 b,and a second side portion 20 c. Similarly, second leg 22 includes afirst side portion 22 a, a bottom surface 22 b, and a second sideportion 22 c and third leg 24 includes a first side portion 24 a, abottom surface 24 b, and a second side portion 24 c. While in thisexample the side portions of the legs are shown disposed at a particularangle with respect to the wire mesh surfaces 12, 14, 16 and 18, itshould be appreciated that the side portions could be formed at anyangle (including a perpendicular angle) with respect to the wire meshsurfaces.

Referring now to FIGS. 3A-3C, diagrams of wire meshes before the wiremesh pallet is formed is shown. The wire meshes includes a plurality ofline wires spaced apart from each other and generally parallel to eachother. The wire meshes also include a plurality of cross wires spacedapart from each other and generally parallel to each other, the crosswires in mechanical communication with the line wires. The cross wiresare generally perpendicular to the line wires. The line wires and thecross wires define a generally rectangular shape for supporting a loadthereon when the mesh is formed into a wire mesh pallet.

Referring now to FIGS. 4A and 4B, a particular embodiment of a wire meshpallet 50 is shown which includes a plurality of bottom wires 54 a-h.Each of the bottom wires is generally parallel to cross wires of thewire mesh and in mechanical communication with line wires of the wiremesh. The bottom wires 54 a-h provide additional support to the meshnear the legs and edges of the wire mesh pallet.

Also shown in FIGS. 4A and 4B are a plurality of runners 56 a-c. Eachrunner is in mechanical communication with a bottom of a first leg and abottom of at least one other leg. Each tapered leg 58, 60 and 62includes a first side surface (58 a, 60 a and 62 a respectively), abottom surface (58 b, 60 b and 62 b respectively) and a second sidesurface (58 c, 60 c and 62 c respectively). In a preferred embodimentthe runner 56 is welded to the bottom surface of the tapered legs 58, 60and 62. The tapered legs allow for nesting of a wire mesh pallet withanother wire mesh pallet.

Also shown in FIG. 4B is a cover 55. Cover 55 may be formed from avariety of materials, including but not limited to rubber, plastic andmetal. The cover is disposed over at least a portion of the top of thewire mesh. The mesh can be thought of as a “skeleton” with the coveracting as a “skin”. The cover can be large enough to cover the entiretop surface of the wire mesh pallet and may further cover at least oneedge of the wire mesh pallet. The cover can be attached by any meansknown to one of ordinary skill in the art. In a particular embodimentthe cover is attached in a similar manner as the runner described belowwith respect to FIGS. 5A-5C. The cover acts a truss device and is usefulfor preventing the spreading or deformation of the wire mesh pallet inresponse to a load being placed on the wire mesh pallet. Preferably thecover 55 is connected to the wire mesh pallet on two or more sides ofthe wire mesh pallet.

Referring now to FIGS. 5A-5C, a particular embodiment of another styleof runner 64 a-c is shown. Each runner 64 a-c comprises a notched stripthat is bent to form around the wires abutting a bottom surface of aleg. The strip is secured in place by any known means, for example arivet. The notches in the strip allow the strip to fit around the legs.

As shown in FIG. 5B, the wire mesh pallet can be formed to include a lip68 extending along at least a portion of at least one side of the wiremesh pallet. The lip 68 or lips provide additional support formaintaining a load on the wire mesh pallet and aid in securing the loadto the wire mesh pallet.

In order to prevent the wire mesh surface and legs from deforming orflexing under load conditions, at least one truss device is added to thestructure. Referring now to FIG. 6, an embodiment of a wire mesh pallet70 is shown. In this embodiment each leg 78, 80 and 82 is fitted with atruss device, in this case a truss leg wire 72 a, 72 b and 72 crespectively. The truss leg wires traverse at least a section of a legof the wire mesh pallet. The truss leg wires provide additional supportfor the legs and prevent spreading or deformation of the leg in responseto a load being placed on the wire mesh pallet 70.

Referring now to FIG. 7, an embodiment of a wire mesh pallet 100 isshown. In this embodiment the wire mesh pallet is fitted with a trussdevice, in this case a truss wire 102. The truss wires traverse at leasta section of the wire mesh pallet. The truss wires provide additionalsupport for wire mesh pallet and prevent spreading or deformation of thewire mesh pallet in response to a load being placed on the wire meshpallet. The truss wire 102 can be placed spanning any amount of space onthe wire mesh pallet and at any angle with respect to the line wires orcross wires.

Referring now to FIG. 8, an embodiment of a wire mesh pallet 120 isshown. In this embodiment the wire mesh pallet is fitted with a trussdevice, in this case truss clips 122 a-c. The truss clips 122 a-ctraverse at least a section of a leg of the wire mesh pallet. The trussclips 122 a-c provide additional support for the legs and preventspreading or deformation of the leg in response to a load being placedon the wire mesh pallet 120.

The truss devices are used to limit or prevent spreading and deformationof the wire mesh pallet when a load is placed on the wire mesh pallet.In some embodiments, it may be desirable to allow a predetermined amountof flex, or to allow an area of the wire mesh pallet to flex while otherareas of the wire mesh pallet have limited or no flex. Also, while thedrawings show a particular number of truss devices, it should berealized that any number of truss devices could be used. Further, thetruss wires may be of any orientation, for example, extending diagonallyacross the wire mesh pallet wherein two diagonal truss wires form an “X”shape.

Referring now to FIGS. 9A and 9B, a particular embodiment of a wire meshpallet 160 is shown which includes additional cross wires 162 a-f whichfunction as bottom wires after the wire mesh pallet is formed. Each ofthe additional cross wires 162 a-f are generally parallel to other crosswires of the wire mesh and in mechanical communication with side of aleg. The additional cross wires 162 a-f provide additional support tothe legs and prevent spreading or deformation of the leg in response toa load being placed on the wire mesh pallet 160.

The wire mesh pallet can be made from a variety of materials, includingbut not limited to steel, stainless steel, aluminum and plastic. Thewire mesh pallet may further be provided with a coating. The coatingprocess can take place before the wire mesh is formed into the wire meshpallet or the coating process can take place after the wire mesh hasbeen formed into a wire mesh pallet.

A flow chart of the presently disclosed method is depicted in FIGS. 10Aand 10B. The rectangular elements are herein denoted “processingblocks”. It will be appreciated by those of ordinary skill in the artthat unless otherwise indicated herein, the particular sequence of stepsdescribed is illustrative only and can be varied without departing fromthe spirit of the invention. Thus, unless otherwise stated, the stepsdescribed below are unordered meaning that, when possible, the steps canbe performed in any convenient or desirable order.

Referring now to FIGS. 10A and 10B, a particular embodiment of a method200 of producing a wire mesh pallet is shown. Method 200 starts withprocessing block 202 which discloses producing a wire mesh. Processingblock 204 states the wire mesh includes a plurality of line wires spacedapart from each other and generally parallel to each other. Processingblock 206 recites the wire mesh also includes a plurality of cross wiresspaced apart from each other and generally parallel to each other, saidcross wires in mechanical communication with said line wires, said crosswires generally perpendicular to said line wires. As shown in processingblock 208, the line wires and the cross wires define a generallyrectangular shape for supporting a load thereon. The wire mesh withvariable, square and/or rectangular spacing may be produced on anautomatic resistance-welding machine or other type device.

Processing block 210 discloses bending the wire mesh at a plurality ofpredetermined locations to form a plurality of support legs. The mesh istypically bent to form three support legs. The gauge of the wire usedand location of the legs will determine the carrying load of the palletand the ability of the pallet to be accessed. There may be “2-way”access in which a fork truck or pallet jack can only access the palletfrom two of the four sides, or “4-way” access wherein the fork truck orpallet jack can access all four sides of the pallet.

Processing block 212 states adding at least one truss device to the wiremesh pallet, the truss device capable of limiting an amount of flex ofthe wire mesh pallet; the truss device in mechanical communication withthe wire mesh pallet, the truss device traversing at least a portion ofthe wire mesh pallet. As shown in processing block 214 the truss devicecomprises a truss wire, the truss wire traversing at least a section ofthe wire mesh pallet. As shown in processing block 216 the truss devicecomprises a truss clip, the truss clip traversing at least a section ofa leg of the wire mesh pallet. As shown in processing block 218 thetruss device comprises a truss leg wire, the truss leg wire traversingat least a section of a leg of the wire mesh pallet. As shown inprocessing block 220 the truss device comprises a cover, the covertraversing at least a section of the wire mesh pallet.

Processing continues on FIG. 10B with processing block 222 which recitesadding a runner, the runner in mechanical communication with a bottom ofa first leg and a bottom of at least one other leg. Processing block 224discloses wherein the wire mesh pallet includes a plurality ofadditional cross wires which function as bottom wires after the wiremesh pallet is formed, the bottom wires generally parallel to the crosswires and in mechanical communication with the line wires. Processingblock 226 states wherein the wire mesh pallet includes a plurality ofadditional cross wires which function as leg reinforcement wires, theleg reinforcement wires in mechanical communication with and extendingalong at least one side of a first leg and one side of a second leg.

Processing block 228 recites coating the wire mesh. As shown inprocessing block 230, the coating is applied before forming the wiremesh pallet. As shown in processing block 232, the coating is appliedafter forming the wire mesh pallet.

The finished pallets can then be nested to maximize the “Cube” in acontainer for both outbound (from the original point of manufacturing)and return shipping (commonly called “Closed loop”).

Unless otherwise stated, use of the word “substantially” may beconstrued to include a precise relationship, condition, arrangement,orientation, and/or other characteristic, and deviations thereof asunderstood by one of ordinary skill in the art, to the extent that suchdeviations do not materially affect the disclosed methods and systems.

Throughout the entirety of the present disclosure, use of the articles“a” or “an” to modify a noun may be understood to be used forconvenience and to include one, or more than one of the modified noun,unless otherwise specifically stated.

Elements, components, modules, and/or parts thereof that are describedand/or otherwise portrayed through the figures to communicate with, beassociated with, and/or be based on, something else, may be understoodto so communicate, be associated with, and or be based on in a directand/or indirect manner, unless otherwise stipulated herein.

Although the methods and systems have been described relative to aspecific embodiment thereof, they are not so limited. Obviously manymodifications and variations may become apparent in light of the aboveteachings. Many additional changes in the details, materials, andarrangement of parts, herein described and illustrated, may be made bythose skilled in the art.

Having described preferred embodiments of the invention it will nowbecome apparent to those of ordinary skill in the art that otherembodiments incorporating these concepts may be used. Accordingly, it issubmitted that that the invention should not be limited to the describedembodiments but rather should be limited only by the spirit and scope ofthe appended claims.

1. A wire mesh pallet comprising: a wire mesh, said wire mesh includinga plurality of integral legs, said legs formed by bending of the wiremesh; and at least one truss device, said truss device capable oflimiting an amount of flex of said wire mesh pallet; said truss devicein mechanical communication with said wire mesh pallet, said trussdevice traversing at least a portion of said wire mesh pallet.
 2. Thewire mesh pallet of claim 1 wherein said truss device comprises at leastone of the group consisting of a truss wire, said truss wire traversingat least a section of said wire mesh pallet; a truss clip, said trussclip traversing at least a section of a leg of said wire mesh pallet; atruss leg wire, said truss leg wire traversing at least a section of aleg of said wire mesh pallet, and a cover, said cover traversing atleast a section of said wire mesh pallet.
 3. The wire mesh pallet ofclaim 1 further comprising a runner, said runner in mechanicalcommunication with a bottom of a first leg and a bottom of at least oneother leg.
 4. The wire mesh pallet of claim 1 wherein said wire meshcomprises: a plurality of line wires spaced apart from each other andgenerally parallel to each other; a plurality of cross wires spacedapart from each other and generally parallel to each other, said crosswires in mechanical communication with said line wires, said cross wiresgenerally perpendicular to said line wires; and wherein said line wiresand said cross wires define a generally rectangular shape for supportinga load thereon.
 5. The wire mesh pallet of claim 1 further comprising aplurality of additional cross wires which function as bottom wires afterthe wire mesh pallet is formed, the bottom wires generally parallel tothe cross wires and in mechanical communication with the line wires. 6.The wire mesh pallet of claim 1 further comprising a plurality of crosswires which function as leg reinforcement wires after the wire meshpallet is formed, the leg reinforcement wires in mechanicalcommunication with and extending along at least one side of a first legand one side of a second leg.
 7. The wire mesh pallet of claim 1 furthercomprising at least one lip, said at least one lip extending along atleast a portion of at least one side of said wire mesh pallet.
 8. Thewire mesh pallet of claim 1 wherein said wire mesh is comprised of amaterial selected from the group consisting of steel, stainless steel,aluminum, and plastic.
 9. The wire mesh pallet of claim 1 furthercomprising a coating.
 10. The wire mesh pallet of claim 9 wherein saidcoating is applied before the bending of said wire mesh.
 11. The wiremesh pallet of claim 9 wherein said coating is applied after the bendingof said wire mesh.
 12. A method of manufacturing a wire mesh palletcomprising: producing a wire mesh; bending said wire mesh at a pluralityof predetermined locations to form a plurality of support legs; andadding at least one truss device to said wire mesh pallet, said trussdevice capable of limiting an amount of flex of said wire mesh pallet;said truss device in mechanical communication with said wire meshpallet, said truss device traversing at least a portion of said wiremesh pallet.
 13. The method of claim 12 wherein said truss devicecomprises at least one of the group consisting of a truss wire, saidtruss wire traversing at least a section of said wire mesh pallet; atruss clip, said truss clip traversing at least a section of a leg ofsaid wire mesh pallet; a truss leg wire, said truss leg wire traversingat least a section of a leg of said wire mesh pallet, and a cover, saidcover traversing at least a section of said wire mesh pallet.
 14. Themethod of claim 12 further comprising adding a runner, said runner inmechanical communication with a bottom of a first leg and a bottom of atleast one other leg.
 15. The method of claim 13 wherein said wire meshcomprises: a plurality of line wires spaced apart from each other andgenerally parallel to each other; a plurality of cross wires spacedapart from each other and generally parallel to each other, said crosswires in mechanical communication with said line wires, said cross wiresgenerally perpendicular to said line wires; and wherein said line wiresand said cross wires define a generally rectangular shape for supportinga load thereon.
 16. The method of claim 13 wherein said wire meshincludes a plurality of additional cross wires which function as bottomwires after the wire mesh pallet is formed, the bottom wires generallyparallel to the cross wires and in mechanical communication with theline wires
 17. The method of claim 13 wherein said wire mesh includes aplurality of cross wires which function as leg reinforcement wires afterthe wire mesh pallet is formed, the leg reinforcement wires inmechanical communication with and extending along at least one side of afirst leg and one side of a second leg
 18. The method of claim 13further comprising coating said wire mesh.
 19. The method of claim 18wherein said coating is applied at a time selected from the groupconsisting of before forming said wire mesh pallet and after formingsaid wire mesh pallet.
 20. The method of claim 18 further comprisingcoating said truss device.